IFB/IFW-i&s-05 INSTALLATION AND SERVICE MANUAL Intelli-Fin® Hot Water Heating Boilers Domestic Hot Water Supply Boilers 1,500,000 — 1,700,000 — 2,000,000 Btu/hr Models FIG. 1 Front View FIG. 2 Rear View Installation and service must be performed by a qualified service installer, service agency or the gas supplier. SPECIAL INSTRUCTIONS TO OWNER WARRANTY NOTE: Factory warranty (shipped with unit) does not apply to units improperly installed or improperly operated.
TABLE OF CONTENTS Warranty .......................................................................... 1 Safety Warnings .............................................................. 3 Codes .......................................................................... 3 Installation Requirements ............................................ 4 Location .................................................................... 4 Clearances ................................................................
A gas appliance that draws combustion air from the equipment room where it is installed must have a supply of fresh air circulating around it during burner operation for proper gas combustion and proper venting. CHECKING EQUIPMENT Upon receiving equipment, check for signs of shipping damage. Pay particular attention to parts accompanying the boiler, which may show signs of being hit or otherwise being mishandled. Verify total number of pieces shown on packing slip with those actually received.
INSTALLATION PROCEDURE LOCATION OF UNIT 1. 2. 3. Locate the appliance so that if water connections should leak, water damage will not occur. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the unit. The pan must not restrict combustion airflow. Under no circumstances is the manufacturer to be held responsible for water damage in connection with this unit, or any of its components.
NOTE Clearances from combustible construction are noted on the appliance rating plate. Maintain minimum specified clearances for adequate operation. All installations must allow sufficient space for servicing the vent connections, water pipe connections, integral circulating pump, bypass piping and other auxiliary equipment, as well as the appliance.
TABLE - B Minimum Recommended Combustion AIR SUPPLY TO MECHANICAL ROOM Combustion Air Source Outside Air* 1 - Opening Inside Air 2 - Openings Btu/hr Input Outside Air* 2 - Openings 1,500,000 375 in2 (2419 cm2) 500 in2 (3226 cm2) 1,500 in2 (9,677 cm2) 1,700,000 425 in2 (2742 cm2) 567 in2 (3658 cm2) 1,700 in2 (10,968 cm2) 2,000,000 500 in2 (3226 cm2) 667 in2 (4303 cm2) 2,000 in2 (12,903 cm2) *Outside air openings shall directly communicate with the outdoors.
All dimensions based on net free area in square inches. Metal louvers or screens reduce the free area of a combustion air opening a minimum of approximately 25%. Check with louver manufacturers for exact net free area of louvers. Where two openings are provided, one must be within 12" (30 cm) of the ceiling and one must be within 12" (30 cm) of the floor of the mechanical room. Each opening must have net free area as specified in Table - B. Single openings shall commence within 12" (30 cm) of the ceiling.
The construction air filter MUST be removed from the appliance’s air inlet before the appliance is placed in normal operation. Once the construction air filter is removed, ensure that either the equipment room is supplied with combustion air from properly sized combustion and ventilation air openings or a combustion air duct from a Direct Vent or Intelli-Vent system is connected to the appliance.
The flue products in the vent system may be cooled below their dew point and form condensate in the flue. The materials used for a Category IV vent must be resistant to any corrosive damage from flue gas condensate. The flue from a Category IV vent system must have a condensate drain with provisions to properly collect and dispose of any condensate that may occur in the venting system.
Any vent materials specified must be listed by a nationally recognized test agency for use as a Category IV vent material. The venting system must be planned so as to avoid possible contact with concealed plumbing or electrical wiring inside walls, floors or ceilings. Locate the appliance as close as possible to a chimney or gas vent. There shall be no reductions in vent diameter. Horizontal portions of the venting system shall be supported to prevent sagging.
the tee. The drain tubing must have a trap provided by a 4" (10.2 cm)-diameter circular trap loop in the drain tubing. Prime the trap loop by pouring a small quantity of water into the drain hose before assembly to the vent. Secure the trap loop in position with nylon wire ties. Use caution not to collapse or restrict the condensate drain line with the nylon wire ties.
10' OR LESS 2' MIN 2' MIN 3' MIN CHIMNEY WALL OR CHIMNEY PARAPET FIG. 15 Vent Termination from Flat Roof - 10 Feet or Less from Parapet Wall FIG. 17 Sidewall Venting Installation The connection from the appliance flue outlet to the sidewall vent cap MUST be made with listed type Category IV vent materials and accessories. The installer must supply suitable vent pipe material. The sidewall vent cap is available from the appliance manufacturer as a vent kit.
The installed sidewall vent cap assembly may be painted to match the exterior color. The opening through the wall for installation of the sidewall vent cap must provide an air space clearance of 2 inches (5.1 cm) around the flue pipe. The diameter of the opening for installation of the sidewall cap will be 4 inches (10.2 cm) larger (minimum) than the nominal diameter of the installed vent pipe to the sidewall cap. The sidewall vent termination must be at least 8 feet (2.
In cold climates, the use of type “B” double wall vent pipe or an insulated single wall pipe for combustion air is recommended to help prevent moisture in the cool incoming air from condensing and leaking from the inlet pipe. Termination point for the flue products must follow the clearance requirements in the Vertical or Horizontal Vent Termination sections of the Category IV Venting. • Galvanized steel vent pipe with joints and seams sealed as specified below.
sealant to ensure a proper seal at the appliance connection and the air inlet cap connection. Dryer vent or flex duct should use a screw type clamp to seal the vent to the appliance air inlet and the air inlet cap. Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants and supplied in proper volume.
Incorrect installation and/or location of the air inlet cap can allow the discharge of flue products to be drawn into the combustion process on the heater. This can result in incomplete combustion and potentially hazardous levels of carbon monoxide in the flue products. This will cause operational problems with the heater and possible spillage of flue products that can cause personal injury, death or property damage. VERTICAL COMBUSTION AIR INLET Multiple Vertical Direct Vent Installations FIG.
The Direct Vent system requires the installation of an additional pipe to supply combustion air from outdoors directly to the appliance. The air inlet pipe must use one of the specified materials. The maximum installed length of the air inlet pipe from the appliance to the air inlet cap is 100 equivalent feet (30.48 m) in length. The maximum installed length of the flue pipe from the appliance to the termination cap is 100 equivalent feet (30.48 m) in length. Subtract 5 feet (1.
The combustion air inlet caps for multiple appliance installations must maintain the same minimum clearance from the closest vent cap installed within a 10 foot (3.05 m) radius of the point of flue gas termination as specified in single appliance installations. Multiple flue outlet caps may be installed side by side and multiple air inlet caps may be installed side by side but the minimum clearance of 3 feet (0.91 m) horizontal radius and 12 inches (0.
Combined Air Inlet Points The air inlet pipes from multiple appliances installed with an Intelli-Vent system can be combined to a single common connection based on the cross sectional area of the common pipe as defined in the Direct Vent basic information section. Termination point for the flue products must follow the clearance requirements in the Vertical Vent Termination section of the Category IV Venting.
Location of a Sidewall Air Inlet Cap Installation, location and clearance requirements for the sidewall air inlet cap in an Intelli-Vent application are the same as the installation, location and clearance requirements for the sidewall air inlet cap in the Horizontal Direct Vent section of the venting instructions. The sidewall combustion air inlet cap and the rooftop flue gas outlet are located in different pressure zones in an Intelli-Vent system.
VERTICAL COMBUSTION AIR INLET HORIZONTAL INTELLI-VENT WITH SIDEWALL COMBUSTION AIR Intelli-Vent systems are installed with a Category IV flue and a separate combustion air pipe to the outdoors. The Horizontal Intelli-Vent system terminates the flue at the sidewall and the combustion air on a sidewall other than the sidewall where the flue is located. The sidewall flue outlet and sidewall combustion air intake must terminate in different pressure zones.
TABLE - J CAUTION Appliances that are shut down or will not operate may experience freezing due to convective airflow in the air inlet pipe connected to the appliance. The flue and air inlet duct sizes for a Horizontal Intelli-Vent Installation with Sidewall Combustion Air Inlet are listed by unit size. SIDEWALL COMBUSTION AIR INLET Intelli-Vent systems installed with sidewall terminations for both combustion air and flue products must purchase the termination caps from the appliance manufacturer.
GAS SUPPLY GAS PRESSURE TEST Verify that the appliance is supplied with the type gas specified on the rating plate. Consult factory for installations at altitude. INLET PRESSURE: Measured at the inlet pressure tap on the appliance gas manifold. The pressure tap is located upstream of the redundant gas valve and down stream of the field installed gas cock. TABLE - K Inlet Gas Pressure Max. (Inches-Water Column) ______________________________ Min. (Inches-Water Column) Natural Gas L. P. Gas 10.5" w.c.
TABLE - M Recommended Gas Pipe Size Single Appliance Installations Distance from Meter Btu/hr 0 - 50 ft. 51 - 100 ft. 101 - 200 ft. 1,500,000 2" 2 1/2" 3" 1,700,000 2 1/2" 2 1/2" 3" 3" 3 1/2" 2,000,000 2 1/2" 3" 3" 3 1/2" 4" 201 - 300 ft. 301 - 500 ft. 3 1/2" For each elbow or tee, add equivalent straight pipe to total length from TABLE - O.
GAS PIPING GAS INLET All gas connections must be made with pipe joint compound resistant to the action of liquefied petroleum and natural gas. All piping must comply with local codes and ordinances. Tubing installations must comply with approved standards and practices. Install Piping to Control The gas line should be a separate line direct from the meter unless the existing gas line is of sufficient capacity. Verify pipe size with your gas supplier.
1. Turn the main power switch to “OFF” position. 2. Shut off gas supply at the manual gas cock in the as piping to the appliance. If fuel supply is LP gas, shut off gas supply at the tank. 3. Remove the 1/8" hex plug from the gas pressure test port located on the inlet gas supply connection at the rear of the appliance. Install a fitting in the inlet pressure tapping suitable to connect to a manometer or magnahelic gauge. Range of scale should be 14 inch w.c. or greater to check inlet pressure. 4.
supply pressure and adjust to ensure a supply pressure between 4.0 and 10.5 inches water column natural gas (13.0" w.c. for propane) while the appliance is firing at 100% of rated input. 7. WATER CONNECTIONS AIR INLET This is a reference pressure only and is not field adjustable. An appliance supplied with a minimum of 4 inches water column of gas supply pressure will operate at the correct manifold pressure as the burner input varies with temperature demand. 8.
Inlet and Outlet Connections For ease of service, install unions on inlet and outlet of the appliance. The connection to the appliance marked “Inlet” on the header should be used for return from the system. The connection on the header marked “Outlet” is to be connected to the supply side of the system. Minimum Pipe Size Requirements Minimum water pipe connections to this appliance is 3 inch (76.2 mm) pipe for single unit installations installed not more than 70 equivalent feet (21.
INTEGRAL BYPASS HOT WATER OUTLET BYPASS VALVE PRIMARY HEAT EXCHANGER PUMP SECONDARY HEAT EXCHANGER COLD WATER INLET FIG. 40 Bypass Piping with Valve Actuator and Pump temperature conformal coating to prevent any corrosive damage to the copper tubes or cast iron headers from the low pH condensate. The protective coating is brown in color and covers both the headers and finned tube surfaces. The secondary heat exchanger is designed to maximize heat transfer efficiency by fully condensing flue products.
BYPASS PIPING ASSEMBLY The primary and secondary heat exchangers are interconnected with a bypass and pump mounted in 2 1/2 inch (63.5 mm) diameter copper pipe. All access to the piping is from the rear of the appliance. On initial start up, all air must be removed from the bypass piping to ensure proper water flow through the appliance. The bypass piping has an air bleed cock located on the discharge side of the internal pump.
TABLE - P Temperature Rise At Full Rate Fire Bypass Manually Fully Closed Btu/hr Input Temperature Rise 1,500,000 _______________________ 1,700,000 _______________________ 31.5°F (17.5°C) _______________________ 35.7°F (19.8°C) _______________________ 2,000,000 42.0°F (23.3°C) 7. The Excel 10 provides 24 VAC to operate a high torque motor in the actuator, which adjusts the position of the floating-point bypass valve. 8.
TABLE - Q Minimum Inlet Water Temperatures Input Btu/hr Minimum Return Temperature A boiler installed above radiation level must be provided with a low water cutoff device either as part of the unit or at the time of installation. Minimum Setpoint 1,500,000 ____________________ 50°F (10°C) 105°F (40.6°C) ___________ _______________ 1,700,000 ____________________ 50°F (10°C) 90°F (32.2°C) ___________ _______________ 2,000,000 50°F (10°C) 70°F (23.
RELIEF VALVE This unit is supplied with a relief valve(s) sized in accordance with ASME Boiler and Pressure Vessel Code, Section IV (“Heating Boilers”). The relief valve(s) is installed in the vertical position and mounted in the hot water outlet. No valve is to be placed between the relief valve, and the unit. To prevent water damage, the discharge from the relief valve shall be piped to a suitable floor drain for disposal when relief occurs.
Venting of Gas Valves and Pressure Switches The diaphragm type gas valve and optional gas pressure switches are provided with threaded termination points to be vented to the atmosphere, outside the building. The gas pressure regulation function is provided by the ratio gas valve which does not require installation of a vent line. The diaphragm gas valve and optional gas pressure switches are installed in the upper chamber of the appliance.
the inner jacket and secondary heat exchanger chamber are also stainless steel. The stainless steel screws are identified by a sealing washer mounted on each screw. DO NOT mix stainless steel and standard plated fasteners when disassembling and reassembling the inner jacket sheet metal components. Standard plated fasteners may be damaged by the flue product condensate when used on the inner jacket assemblies. Outer Jacket - The outer jacket assembly is constructed from steel, galvanized on both sides.
FIG. 48 Transformer and Relay Locations VARIABLE FREQUENCY DRIVE FIG. 49 Internal Control Panel Location A transformer and relay mounting panel is located above the front control panel, underneath the curved exterior front jacket panel. This panel contains a 100 VA transformer to drop 120 VAC to 24 VAC for internal control operation, an optional electronic low water cut-off, a high limit alarm relay, an alarm relay, an ignition relay, gas valve relay, pump relay, louver relay and VFD power relay. FIG.
blower from 25% up to 100% of capacity corresponding to the same variation in burner input. The output from the Excel 10 to the variable frequency drive ensures that combustion air and gas are always supplied in the proper ratio for clean combustion. The variable frequency drive is driven to 100% during the pre-purge portion of the start-up sequence. The variable frequency drive is then provided a signal to operate at 50% for initial burner ignition.
Excel 10 Boiler Interface Controller - The boiler interface controller for this appliance is based on the Excel 10 controller platform with unique software customized for operation of the Lochinvar Intelli-Fin. The Excel 10 is also compatible with LonWorks® building management systems. All of the appliances’ internal safety, operating and ignition controls interface with the Excel 10 controller.
is unique to each Excel 10 and must be placed into the network of an energy management system so that the Excel 10 can be recognized by the system. NOTE: If the Excel 10 is ever replaced, a tear-off label on the new Excel 10 must be placed over this label on the back of the unit for easy reference. The Excel 10 may have values for the control points specified at the time the control is configured at the factory.
The Command Display provides a communication interface with the Excel 10 via a series of display screens. The front view of the display screen shows the digital display with a cluster of arrow keys on the lower left side. These directional arrow keys move the cursor in the direction of the arrow. NOTE: Once a password is correctly entered, it will not have to be reentered unless five minutes of inactivity on the Command Display has elapsed.
to drop lower (Changeable Command Display). NOTE: Allow 10 seconds for data shown in the display screens to update when viewing or making adjustments to any of the six adjustable points. POINTS FROM INFORMATION VISIBLE FROM THE SCREEN OF THE COMMAND DISPLAY 1. 2. 3. 4. 5. Calculated Set Point — The water temperature as adjusted by an optional outdoor reset function used on a heating boiler only. If no outdoor reset function is used, this displays the same temperature as the set point.
FIG. 56a Command Display Data Screen FIG. 56d Command Display Data Screen FIG. 56b Command Display Data Screen FIG. 56e Command Display Data Screen FIG. 56c Command Display Data Screen FIG.
POWER-UP AND NAVIGATION BETWEEN THE SCREENS OF THE COMMAND DISPLAY The first screen is viewable on the Command Display as it is powered up. This Command Display screen gives the current software version running on the Excel 10. This screen goes away after 60 seconds. The amount of time until this screen changes is displayed on the bottom left of the screen in a numeric count. After the 60 seconds expires or when the user presses any key during this interval, the next screen is displayed.
Pressing the Back key will return you to the Heat Source display. The up and down arrow keys can be used to scroll the cursor up and down to the various heat sources (boilers or water heaters) at this location. To the right of each heat source displays the operational status of the individual appliance. Pressing the Select key when the cursor is on a specific heat source displays the parameters for this boiler or water heater.
Setpoint Temp — This is the lowest boiler operating temperature that the boiler will maintain when the outside air temperature is at the O.A. Max. This setting is a Changeable Point from the Command Display. Calculated Set Point — The water temperature as adjusted by the optional outdoor air reset function used on a heating boiler only. If no outdoor reset function is used, this displays the same temperature as the set point. The Outdoor Air Reset function is not available on a water heater application.
star, loop and/or bus wiring. The maximum number of nodes per segment is 60. The maximum number of nodes in a two-segment FTT network is 120, when using a repeater between the two segments. Consult factory for additional information on interface wiring of multiple Intelli-Fin appliances connected to an EMS. INTERFACING MULTIPLE APPLIANCES PARALLEL CONNECTION FTT networks are flexible and convenient to install and maintain.
STRIP 1/2" FROM WIRE TO BE ATTACHED. 1/2" (13MM) INSERT TWISTED WIRES UNDER TERMINAL AND TIGHTEN. CHECK FOR A GOOD MECHANICAL CONNECTION. TWIST WIRES TOGETHER WITH PLIERS (MINIMUM OF THREE TURNS) FIG. 60 Wire Termination for E-Bus Connection 1. Strip 1/2 in. (13 mm) insulation from the conductor. 2. Insert the wire in the required terminal location and tighten the screw to complete the termination. 3.
FIG. 61 Typical Building Management System Diagram HIGH WATER TEMPERATURE LIMIT CONTROL A Manual Reset High Limit control is located on the left front side of the control panel, beside the Command Display. Additional switches, alarm indicating lights and optional low water cut-off control switches are also located on this panel. The setting of this control knob limits maximum discharge water temperature.
HOT SURFACE IGNITION SYSTEM IGNITION CONTROL MODULE OEM unit only. An OEM specification igniter and ignition control module for this specific unit is available from your local distributor. DO NOT use general purpose field replacement ignition modules or igniters. Each appliance has one ignition module and one hot surface igniter. Ignition Module Lockout Functions DIAGNOSTIC STATUS CODES FIG. 63 Hot Surface Ignition Control Module This appliance uses a proven hot surface ignition control system.
Diagnostic Status Indication TABLE - Y Ignition and Control Timings The ignition module has an LED that indicates the status of the ignition safety circuits. The flashing operation of this LED indicates the diagnostic status of the ignition control module. The following listing gives the flashing diagnostic status codes as signaled by the ignition module. Proven Pilot Hot Surface Ignition System Pre-purge Time 15 Seconds D. C.
OPERATION/DIAGNOSTIC LIGHTS, RESETS AND SWITCHES ADJ HI-LIMIT BURNER CIRCUIT BREAKER ALARM RESET ALARM SOUND ALARM POWER SILENCE LOW WATER CUT-OFF AUTO RESET TEST MANUAL FIG. 66 Exterior Control Panel FIG. 67 Burner Assembly The control panel has a lighted ON/OFF power switch and 11 indicating lights and switches to show operation, control sensed malfunctions and diagnostics. TABLE - AA Diagnostic Lights and Switches Indicator Function Power Lighted ON/OFF Main Power Switch.
This appliance uses a single cylindrical burner installed vertically into the cavity located in the center of the primary heat exchanger. There is a unique burner for each one of the three models. Burners may NOT be changed between different Btu/hr input models. The burner consists of a round mounting flange welded to a mixing tube. The top side of the mixing tube provides the transition which mounts the discharge from the combustion air blower into the burner.
FILTER FIG. 70 ACCESS PLATE This high efficiency appliance may operate as a condensing appliance for extended periods of time based on return water temperatures. Condensate occurs when the products of combustion are cooled below their dew point in the heat transfer process. The liquid condensate formed from this high efficiency heat transfer process is mildly acidic. The condensate will typically have a pH ranging from 4.0 to 5.0 as it is discharged from the condensate drain on the rear of the appliance.
Many codes will require the acidic condensate to be neutralized before it can be placed in a drain system. The optional condensate management system consists of a neutralizer kit to control the pH of the liquid discharged to a drain system. The neutralizer in the condensate management system consists of an industrial grade, non-corrosive plastic reservoir for collection of the condensate. The reservoir is charged with a reagent grade calcium carbonate.
WARNING LIGHTING INSTRUCTIONS Use a level to ensure that the condensate trap is level on its base. Failure to keep the condensate trap level can result in the spillage of flue products from the condensate trap. FOR YOUR SAFETY, READ BEFORE OPERATING Failure to follow this warning could result in product damage or improper operation, personal injury, or death. NOTE: WARNING Use materials approved by the authority having jurisdiction.
8. Turn on all electric power to the appliance. 9. Set the Temperature Set Point function of the Command Display to the desired setting. 10. If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance” and call your service technician or gas supplier. LIGHTING INSTRUCTIONS 1. STOP! Read the safety information. 2. Set the Temperature Set Point function of the Command Display to the lowest setting. 3. Turn Off all electrical power to the appliance. 4.
SEQUENCE OF OPERATION 1. The power switch is placed in the “ON” position and the run/stop switch is in the “RUN” position. 2. 120 VAC Power is supplied to the control junction box and to the integral pump. 3. 120 VAC Power is supplied to the Transformer, Ignition Module and Excel 10. will synchronize 19. Variable Ratio Gas Valve senses the pressure from the Combustion Air Blower and supplies gas to the orifice and into the Blower inlet to pre-mix. 20.
32. Rate of flue product movement is controlled by “V” Baffles on the heat exchanger to maximize heat transfer. 33. Heated products of combustion then pass over the Secondary Heat Exchanger to absorb additional heat. 34. Flue products pass into the flue collector and are exhausted from the unit. NORMAL BURNER FLAME End of Sequence 35. Set Point temperature is satisfied. 36. Power to the gas valves is turned off. 37.
c. Remove the outer control panel cover. Open the control panel and remove the screws from the lower front edge of the radiused front outer jacket panel. Lift the edge of the radiused panel and locate the internal screws attaching the back edge of the radiused panel. Reach through the control panel opening with a 5/16” nut driver and loosen the 2 internal screws holding the rear edge of the radiused panel. Pull the panel slightly forward and remove it.
NOTE: When the combustion air blower is removed for any reason, the inlet to the burner must be covered to prevent foreign objects from falling into the burner. A foreign object such as a nut, bolt, wire or other metallic items will cause a rapid non-warrantable failure of the burner on operation. NOTE: Use care when removing and handling the burner. Sharp objects or impact may damage or tear the woven burner flame surface.
G. SECONDARY HEAT EXCHANGER INSPECTION NOTE: All gaskets/sealant on disassembled components or jacket panels must be replaced with new gaskets/ sealant on reassembly. Gasket and sealant kits are available from your distributor. F. PRIMARY HEAT EXCHANGER INSPECTION 1. Turn off all power to the appliance. 2. Turn off main gas to appliance. 3. Remove the front outer jacket door. 4. Remove the front inner jacket door. 5. Check the heat exchanger surface for soot.
10. Carefully reinstall the heat exchanger if removed from the appliance. ORIFICE GAS Reinstall inner rear jacket panels, bypass piping and condensate hoses. Use new gasket material to ensure a proper air seal. AIR BOX (FRONT VIEW) BLOWER 9. GAS AIR 11. Reassemble all water piping. Test for leaks. 12. Reassemble rear outer jacket panels. GAS 3.5" W.C. = Pair GAS 13. AIR GAS VALVE (TOP VIEW) Cycle unit and check for proper operation. MANIFOLD AIR PRESSURE H.
4. As the appliance comes on and fires, record the inches of water column of displacement on both sides of the manometer. The sum of these two readings as they are effected by the two air pressures is the differential air pressure. FREEZE PROTECTION Installations are not recommended in areas where the danger of freezing exists. Proper freeze protection must be provided for appliances installed in unheated mechanical rooms or where temperatures may drop to the freezing point or lower.
(d) Drain the unit completely. Remove the caps from the two drains located on the rear of the appliance. Open the relief valve and manually open the bypass valve to allow air into the system so the water will drain out. Open the union fitting on the inlet so water can be drained from the secondary heat exchanger. (e) Ensure that the pump, bypass piping and connecting piping are fully drained. FREEZE PROTECTION FOR A HEATING BOILER SYSTEM (If Required) 1.
PIPING LENGTHS PRIMARY LOOP CIRCULATOR PUMP SPECIFICATIONS The boiler’s integral circulator provides the water flow from the primary boiler piping, through the boiler and back to the primary system. Pipe diameter and length are critical to ensure proper flow through the boiler. A 3 inch (76.2 mm) diameter pipe installed from the primary system to the boiler inlet must not exceed 70 equivalent feet (21.2 m) in length.
PRIMARY/SECONDARY BOILER PIPING TO SYSTEM TO EXPANSION TANK AND MAKEUP WATER SYSTEM 12” MAX. FROM SYSTEM FIG. 80 Primary/Secondary Piping of a Single Boiler MAKE-UP WATER A properly sized primary system pump provides adequate flow to carry the heated boiler water to radiation, air over coils, etc. The fittings that connect the boiler to the primary system should be a maximum of 12" (0.30 m) (or 4 pipe diameters) apart to ensure connection at a point of zero pressure drop in the primary system.
The automatic bypass system allows part of the boiler discharge water to be mixed with the inlet water to the primary heat exchanger to increase the boiler inlet temperature above 130°F (55°C). This will prevent the products of combustion from condensing on the primary heat exchanger. A valve must also be provided on the boiler discharge, after the bypass. Closing this discharge valve sets the maximum flow through the appliance. (See Bypass—Initial Set-up of Maximum Water Flow for more details.
TEMPERATURE/PRESSURE GAUGE This boiler is equipped with a dial type temperature/pressure gauge. This gauge is factory installed in the outlet side of the boiler bypass piping. The gauge has one scale to read system pressure and a separate scale to read water temperature in °F. The temperature/pressure gauge is provided to meet code requirements. Water temperatures can be more accurately monitored from the data provided in the Command Display. TYPICAL HEATING BOILER INSTALLATIONS 9. Check system pressure.
Boiler Operation 28. Turn the run/stop switch to the “RUN” position to start boiler operation. 29. Push the resets for low water level, high water temperature and flame failure. 30. Observe the boiler synchronization process before start-up of the boiler begins. 31. Boiler should begin the start-up process for the sequence of operation. 32. The boiler will fire at 50% of rated input on initial start-up and adjust input as required to meet system demand. 33.
DOMESTIC HOT WATER SUPPLY BOILER This section applies only to those appliance used to supply domestic hot water, installed with a storage tank(s). The integral circulating pump installed in the bypass piping assembly is used to control water velocity through the appliance. Proper water velocity is important for correct operation of your water heater or hot water supply boiler.
TABLE - EE TABLE - FF Maximum Flow Rate Temperature Rise At Full Rate Fire Bypass Manually Fully Closed Btu/hr Input 1,500,000 - 2,000,000 Maximum Flow Btu/hr Input 90 GPM If higher flow rates are required through the water heater, an optional Cupro-Nickel heat exchanger is available. Consult the factory for specific application requirements. The heat exchanger is capable of operating within the design flow rates required for the water heater, storage tank(s) and connecting piping.
5. 6. Be sure the pipes between the water heater or hot water supply boiler and storage tank are not less than 3 inch (76.2 mm) diameter for up to 70 equivalent feet (21.2 m) of pipe to and from the heater. If maximum equivalent length for the specified pipe diameter is exceeded, larger diameter pipe may have to be installed to achieve correct flow and temperature rise.
PIPING - MULTIPLE UNIT INSTALLATIONS MIXING VALVE BUILDING HOT WATER SUPPLY RELIEF VALVE TO DRAIN LOCK-TEMP STORAGE TANK COLD WATER SUPPLY DRAIN BUILDING RETURN FIG. 84 Single Water Heater Piping with Two Storage Tanks MIXING VALVE COLD WATER SUPPLY LOCK-TEMP STORAGE TANK BUILDING HOT WATER SUPPLY RELIEF VALVE TO DRAIN MIN. 3” (75mm) COMMON MANIFOLD SIZE DRAIN BUILDING RETURN FIG.
6. TABLE - GG Common Water Manifold Size For Multiple Water Heater Hot Water Supply Boiler Installations Btu/hr Input Temperature Rise Pipe sizing chart provides minimum pipe size for common manifold piping to ensure adequate flow.
THERMOSTAT SETTINGS 1. 2. TABLE - HH Minimum Inlet Water Temperatures The Excel 10 temperature controller is adjusted to a low test setting when shipped from the factory. Input Btu/hr Using the Command Display, adjust the temperature set point to the lowest settings which will satisfy hot water demands and prevent a risk of scald injury.
NOTE: (1) This water heater, when set at the lower temperature setting, is not capable of producing hot water of sufficient temperature for sanitizing purposes. (2) Higher stored water temperature increases the ability of the water heater to supply desired quantities of hot water, however rememberIncorrect piping of the cold water supply to the system may result in excessive low temperature operation causing condensate formation on the primary heat exchanger and operational problems.
Ladder Diagram 1,500,000 - 1,300,000 - 2,000,000 Btu/hr Models WARNING:To avoid possible shock hazard, disconnect power before servicing. HOT NEUTRAL UNIT POWER 120VAC 15AMP GROUND M VFD GND NO G COM T1 T2 T3 L1 BLOWER ASSEMBLY L2 POWER SWITCH N 7 2 C VFD POWER RELAY 3 NO R L1 PUMP POWER 120VAC 15AMP L2 OPTIONAL S1 GROUND PUMP MOTOR S2 M IGNITION MODULE COM 1 2 COM EXT.
Wiring Diagram 1,500,000 - 1,300,000 - 2,000,000 Btu/hr Models BK W CHASSIS GROUND BL BR GY GY FAN CIRCUIT BREAKER VFD POWER RELAY BK R NO BK/W COM BL PUMP POWER 120VAC 15AMP BL PU OVER TEMP INDICATOR Y NC R NO PU BL/ BK HI-LIMIT ALARM RELAY BK W G ALARM INDICATOR BL/W Y PU ALARM RELAY ~ ~~~ ~~ ~ ~~ ~~~ STD.
Wiring Diagram (continued) 1,500,000 - 1,300,000 - 2,000,000 Btu/hr Models BK W Y BL BR BR Y LOUVER RELAY WARNING:To avoid possible shock hazard, disconnect power before servicing.
Revision Notes: Rev. 4 (IFB/IFW-i&s-04) reflects additional text on Page 39, changes made to Figures 47 & 48, Table AA (Page 51), and LBLs on Pages 77-79. Revision 5 (ECO #C02870) reflects changes made to the scald section, pages 70, 73, and 75, the addition of a mixing valve to the piping diagrams (FIG’s 83 - 86), edits made to FIG. 80 (pg. 66), and a title change on FIG.’s 3 and 4 on page 4. 80 1/09-Printed in U.S.A.